Footwear uppers and other textile components including reinforced and abutting edge joint seams

ABSTRACT

Textile Components, such as upper members for articles of footwear, include: (a) a first portion having a first edge, wherein the first edge includes a first portion of material engaged with a first seam support material via a first thermoplastic material; (b) a second portion having a second edge, wherein the second edge includes a second portion of material engaged with a second seam support material via a second thermoplastic material; and (c) structure to engage the first and second edges in an abutting edge joint (such as a zig-zag stitch). The resulting textile components may be lightweight and breathable (e.g., due to use of lightweight upper fabric), having a comfortable fit (e.g., due to the abutting edge joint), while still providing a strong, stable, and durable construction (e.g., due to the presence of the seam support member(s)).

FIELD OF THE INVENTION

This invention relates generally to features of textile components(e.g., upper members for articles of footwear) and articles ofmanufacture (e.g., articles of footwear) produced including such textilecomponents. Such features may include features of the textile componentconstruction and seams used in making the textile components.

BACKGROUND

Conventional articles of athletic footwear have included two primaryelements, namely an upper member and a sole structure. The upper memberprovides a covering for the foot that securely receives and positionsthe foot with respect to the sole structure. In addition, the uppermember may have a configuration that protects the foot and providesventilation, thereby cooling the foot and removing perspiration. Thesole structure generally is secured to a lower portion of the uppermember and generally is positioned between the foot and the ground. Inaddition to attenuating ground or other contact surface reaction forces,the sole structure may provide traction and control foot motions, suchas pronation. Accordingly, the upper member and sole structure operatecooperatively to provide a comfortable structure that is suited for avariety of ambulatory and athletic activities, such as walking andrunning.

The sole structure of athletic footwear generally exhibits a layeredconfiguration that includes a comfort-enhancing insole, a resilientmidsole formed from a polymer foam material, and a ground-contactingoutsole that provides both abrasion-resistance and traction. The midsoleis the primary sole structure element that attenuates ground reactionforces and controls foot motions. Suitable polymer foam materials forthe midsole include ethylvinylacetate or polyurethane that compressresiliently under an applied load to attenuate ground reaction forces.

Footwear construction and production typically involve various competinginterests. For example, if one uses a fabric for the upper that is heavyand strong enough to provide sufficient durability and structuralsupport for all of the necessary stitching and seams, the fabric tendsto be heavy, dense, stiff, and non-breathable. Lightweight fabrics, onthe other hand, while often providing the desired breathabilitycharacteristics, tend to be insufficiently durable and unable toadequately support seams necessary for forming a durable, long lastingupper member. Lightweight and breathable upper constructions thatprovide a high level of foot comfort and a stable and durable upperconstruction would be welcome in this art.

SUMMARY

The following presents a general summary of aspects of the invention inorder to provide a basic understanding of the invention and variousfeatures of it. This summary is not intended to limit the scope of theinvention in any way, but it simply provides a general overview andcontext for the more detailed description that follows.

Aspects of this invention relate to textile components that include: (a)a first material element having a first edge, wherein the first edgeincludes a first portion of material engaged with a first seam supportmaterial via a first thermoplastic material; (b) a second materialelement having a second edge, wherein the second edge includes a secondportion of material engaged with a second seam support material via asecond thermoplastic material, wherein the second thermoplastic materialmay be the same as or different from the first thermoplastic material,and wherein the second seam support material may be the same as ordifferent from the first seam support material; and (c) means forengaging the first edge and the second edge in an abutting edge joint.

Some more specific aspects of this invention relate to features of uppermembers for articles of footwear. Upper members in accordance with atleast some examples of this invention may include: (a) a first upperportion having a first edge, wherein the first edge includes a firstportion of upper material engaged with a first seam support material viaa first thermoplastic material; (b) a second upper portion having asecond edge, wherein the second edge includes a second portion of uppermaterial engaged with a second seam support material via a secondthermoplastic material, wherein the second thermoplastic material may bethe same as or different from the first thermoplastic material, andwherein the second seam support material may be the same as or differentfrom the first seam support material; and (c) means for engaging thefirst edge and the second edge in an abutting edge joint. The means forengaging may include producing a seam by sewing or stitching (such asvia a zig-zag stitch), fusing techniques (e.g., using heat, pressure,laser radiation, radio frequency, etc.), mechanical connectors, etc. Anabutting edge joint is desirable because it provides a non-overlappingjoint, which provides a smooth and comfortable surface for contactingthe wearer's foot.

The material for the upper or other textile components may include anydesired materials, including conventional materials for upper members asare known and used in the art. In some examples of this invention, thematerial will constitute a lightweight, breathable fabric, such as aspacer mesh material. In some instances, fabric materials will beselected that are not, by themselves, capable of stably supporting asewn seam (e.g., the stitches of the seam will tend to easily pullthrough or tear the fabric thereby separating the seam), for example,thin or lightweight fabrics that provide excellent breathability but arenot particularly strong. As another example, if desired, the uppermaterial may include high strength threads or other reinforcing and/orshape defining structures at selected locations in the upper materialconstruction (such as the high strength thread used in various FLYWIRE™footwear products available from NIKE, Inc. of Beaverton, Oreg., heelcounters, etc.).

The seam support material may be any desired material capable ofsupporting a seam, such as leather, synthetic leather, suede, non-wovenmaterials (such as Ecsaine® an ultra-microfiber, suede-like, non-wovenfabric material commercially available from Toray Industries, Inc.),thick textile fabric materials, etc. While strong and capable ofsupporting a seam, the seam support material is not necessarily veryabrasion resistant or breathable.

The thermoplastic material is used to bond the seam support material tothe upper or other textile material. The thermoplastic material mayconstitute a thermoplastic film material that is first applied to theseam support material and optionally cut to a desired shape (along withthe seam support material). The thermoplastic film material may beadhered to the seam support material, for example, via an adhesive. Thecombined thermoplastic film material and seam support material (alsocalled a “seam support member” herein) then may be applied to the upperor other textile material at a desired location (e.g., so that edges ofthe seam support member are layered with corresponding edges of theupper or other textile material). The layered materials then are treated(e.g., under heat, pressure, ultrasound, and/or radiation exposureconditions) to essentially bind (or “weld”) the seam support material tothe upper or other textile material via the thermoplastic material. Somespecific examples of thermoplastic materials that may be used in suchconstructions include thermoplastic seam tapes and Sewfree®thermoplastic materials available from Bemis Associates, Inc.

If desired, in accordance with at least some examples of this invention,the seam support material itself may have adhesive properties (e.g.,such as a thermoplastic material) that allow it to be directly engagedwith the upper or other textile material (e.g., using heat and/orpressure treatments) without the need for an additional separatethermoplastic layer (e.g., a separate thermoplastic film as describedabove).

Aspects of this invention further relate to articles of manufacture(such as footwear) including textile components (such as upper members)of the types described above and to methods of making seams, textilecomponents, upper members, articles of manufacture, and articles offootwear utilizing one or more abutting edge joints as described above.Footwear uppers in accordance with at least some examples of thisinvention may provide a lightweight and breathable upper construction(e.g., due to the use of lightweight and breathable upper fabricmaterials), having a comfortable fit (e.g., due to the abutting edgejoint structure), while still having a strong, stable, and durableconstruction (e.g., due to the presence of the seam support member(s))and/or an interesting aesthetic appearance (e.g., due to patterns andfeatures of the seam support material on the remainder of the uppermaterial).

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention and certainadvantages thereof may be acquired by referring to the followingdetailed description in consideration with the accompanying drawings, inwhich:

FIG. 1 illustrates construction of an example spacer mesh upper materialthat may be used in at least some examples of this invention;

FIG. 2 illustrates an example of cutting an upper material from an uppermaterial blank in accordance with at least some examples of thisinvention;

FIG. 3 illustrates an example cut out upper material in accordance withthis invention;

FIG. 4 illustrates construction of an example seam support membermaterial that may be used in at least some examples of this invention;

FIG. 5 illustrates an example of cutting a seam support member from aseam support material blank in accordance with at least some examples ofthis invention;

FIG. 6 illustrates an example seam support member in accordance withthis invention;

FIGS. 7A and 7B illustrate construction of an example upper member,including composite edge areas to be joined by an abutting edge joint,in accordance with this invention;

FIGS. 8A through 8E illustrate example steps involved in producing anabutting edge joint in accordance with this invention;

FIG. 9 illustrates various alternative features of an upper memberconstruction that may be used in at least some example structuresaccording to this invention; and

FIGS. 10A through 10C illustrate an example article of footwear,including various example features and structures in accordance withthis invention.

The reader is advised that the attached drawings are not necessarilydrawn to scale.

DETAILED DESCRIPTION

In the following description of various example structures in accordancewith the invention, reference is made to the accompanying drawings,which form a part hereof, and in which are shown by way of illustrationvarious example seams, joints, upper members, and footwear structures inaccordance with the invention. Additionally, it is to be understood thatother specific arrangements of parts and structures may be utilized, andstructural and functional modifications may be made without departingfrom the scope of the present invention. Also, while the terms “top,”“bottom,” “front,” “back,” “rear,” “side,” “underside,” “overhead,” andthe like may be used in this specification to describe various examplefeatures and elements of the invention, these terms are used herein as amatter of convenience, e.g., based on the example orientations shown inthe figures and/or the orientations in typical use. Nothing in thisspecification should be construed as requiring a specific threedimensional or spatial orientation of structures in order to fall withinthe scope of this invention.

In general, as described above, aspects of this invention relate totextile elements, such as upper members for articles of footwear,including seam structures used in forming products from such textilematerials. Specific examples of the invention are described in moredetail below. The reader should understand that these specific examplesare set forth merely to illustrate examples of the invention, and theyshould not be construed as limiting the invention.

A. GENERAL DESCRIPTION OF ASPECTS OF THIS INVENTION

1. Upper Structures and Other Textile Components

As noted above, in general, aspects of this invention relate to featuresof textile components, such as upper members for articles of footwear.Such textile components may include: (a) a first material element havinga first edge, wherein the first edge includes a first portion ofmaterial engaged with a first seam support material via a firstthermoplastic material; (b) a second material element having a secondedge, wherein the second edge includes a second portion of materialengaged with a second seam support material via a second thermoplasticmaterial, wherein the second thermoplastic material may be the same asor different from the first thermoplastic material, and wherein thesecond seam support material may be the same as or different from thefirst seam support material; and (c) means for engaging the first edgeand the second edge in an abutting edge joint. The means for engagingthe first edge and the second edge may include various structures, suchas a sewn seam (e.g., having a zig-zag stitch structure). Optionally, ifdesired, the thread material of the sewn seam may be at least partiallymelted, absorbed, concealed, or masked. The thermoplastic materials maybe integrally included as part of the seam support materials or they maybe separately applied to the seam support materials (e.g., as athermoplastic film).

Footwear upper members in accordance with at least some examples of thisinvention may include: (a) a first upper portion having a first edge,wherein the first edge includes a first portion of upper materialengaged with a first seam support material via a first thermoplasticmaterial; (b) a second upper portion having a second edge, wherein thesecond edge includes a second portion of upper material engaged with asecond seam support material via a second thermoplastic material (thesecond thermoplastic material may be the same as or different from thefirst thermoplastic material and the second seam support material may bethe same as or different from the first seam support material); and (c)means for engaging the first edge and the second edge in an abuttingedge joint. The means for engaging may include producing a seam bysewing or stitching (such as via a zig-zag stitch), fusing techniques(e.g., using heat, pressure, ultrasonic radiation, laser radiation,radio frequency energy, etc.), mechanical connectors, adhesives, etc. Ifdesired, the thread material used in making the sewn or stitched seam(e.g., the thread of the zig-zag stitch) may be made from a suitablematerial such that it can be at least partially melted, absorbed,concealed, or masked in the final seam structure. For example, ifdesired, the thread material may be made from a thermoplasticpolyurethane material that can be essentially melted into anothermaterial of the abutting edge joint (such as the seam support material)by application of one or more of heat, pressure, laser radiation, radiofrequency energy, etc.

The upper member or other textile element may be made from one or moreseparate pieces without departing from this invention. Similarly, thevarious parts of the abutting edge joint may be located on a singlepiece of material or on separate pieces of material without departingfrom this invention. If desired, when used as an upper material, theupper material also may form at least a portion of the footbed for anarticle of footwear. In some example structures according to thisinvention, however, at least one of the first upper portion or thesecond upper portion may be engaged with a strobel member that forms atleast a portion of a footbed for an article of footwear. Additionally oralternatively, if desired, either or both of the first upper portion orthe second upper portion may include a piece of material positioned andarranged to be used as a tongue member for the article of footwear inthe finally assembled upper member.

The material elements used in forming seams in accordance with thisinvention may have a variety of properties and characteristics. Forexample, a major component of the upper or textile element may be alightweight and highly air permeable material that is not necessarilystrong enough to reliably support a seam, whereas the seam supportmaterial (e.g., prior to applying a thermoplastic material thereto) thatis applied to the major component of the upper or textile element mayhave higher strength properties (e.g., a high tear strength). In someexample constructions in accordance with this invention, the majorcomponent of the upper or textile element will include a fabric ortextile having an air permeability characteristic (as measured by ASTMD737-96) of at least 15 cubic feet/min/square foot, and in some examplestructures the air permeability of this element will be at least 30cubic feet/min/square foot, at least 60 cubic feet/min/square foot, oreven at least 100 cubic feet/min/square foot. The seam support material,on the other hand, may have an air permeability characteristic that isat least 25% less, and in some examples at least 50% less or even atleast 75% less than that of the more air permeable component of theupper or textile element to which it is engaged.

As another example, in some seam structures in accordance with thisinvention, the major component of the upper or textile element willinclude a fabric or textile having a weight of less than 10 oz/yd², andin some example structures the weight of this element will be less than7.5 oz/yd², less than 5 oz/yd², or even less than 3 oz/yd². The seamsupport material, on the other hand, may have a weight characteristicthat is at least 25% more, and in some examples at least 50% more, atleast 75% more, at least 100% more, or even at least 150% more than thatof the lighter weight component of the upper or textile element to whichit is engaged.

As another characteristic, if desired, the major component of the upperor textile element may include a fabric or textile having a tearstrength characteristic (as measured by ASTM D2261) of less than 15 lbs,and in some example structures the tear strength of this element will beless than 10 lbs, less than 7 lbs, less than 5 lbs, or even less than 3lbs. The seam support material, on the other hand, may have a tearstrength that is at least 25% more, and in some examples at least 50%more, at least 75% more, at least 100% more, or even at least 150% morethan that of the component of the upper or textile element to which itis engaged.

Additional potential structural features and specific examples of uppermembers in accordance with examples of this invention will be describedin more detail below.

2. Articles of Footwear

Additional aspects of this invention relate to articles of footwear thatincorporate upper members of the types described above. As more specificexamples, articles of footwear according to at least some examples ofthis invention may include: (a) an upper member composed of one or moreupper pieces, wherein the upper member includes at least one seam madefrom a first edge of the upper member engaged with a second edge of theupper member in an abutting edge joint, wherein the first edge of theupper member includes a first portion of upper material engaged with afirst seam support material via a first thermoplastic material, whereinthe second edge of the upper member includes a second portion of uppermaterial engaged with a second seam support material via a secondthermoplastic material (the second thermoplastic material may be thesame as or different from the first thermoplastic material and thesecond seam support material may be the same as or different from thefirst seam support material); and (b) a sole structure engaged with theupper member. As also described above, the upper member may include astrobel member, a tongue portion, and the like, including any of thefeatures or characteristics described above or described in more detailbelow.

Any desired sole structure construction may be used without departingfrom this invention. For example, the sole structure may include one ormore of: an insole element or a sock liner (in addition to or as areplacement for the strobel member mentioned above); a midsole member(e.g., made from polyurethane or ethylvinylacetate foams, includingfluid-filled bladders, including impact force attenuating columns,including other impact force attenuating elements or structures, etc.);an outsole member engaged with the midsole member; etc. The solestructure may be engaged with the upper member in any desired mannerwithout departing from this invention, including through the use ofengagement techniques that are conventional, known, and used in the art,including through the use of one or more of: adhesives or cements,fusing techniques, mechanical connectors, or the like.

Additional potential structural features and specific examples ofarticles of footwear in accordance with examples of this invention willbe described in more detail below.

3. Methods

Further aspects of this invention relate to methods of forming seams intextile components. Such methods may include: (a) providing a textilecomponent including a first portion having a first exposed edge and asecond portion having a second exposed edge, wherein the textilecomponent may be composed of one or more separate pieces; (b) providinga first seam support member including a first thermoplastic material,wherein the first seam support member is shaped to include a thirdexposed edge that matches at least a portion of the first exposed edge;(c) providing a second seam support member including a secondthermoplastic material, wherein the second thermoplastic material may bethe same as or different from the first thermoplastic material, andwherein the second seam support member is shaped to include a fourthexposed edge that matches at least a portion of the second exposed edge;(d) placing the first seam support member on the first portion of thetextile component such that the first exposed edge and the third exposededge are in a layered relationship and such that the first thermoplasticmaterial contacts the first portion of the textile component; (e)placing the second seam support member on the second portion of thetextile component such that the second exposed edge and the fourthexposed edge are in a layered relationship and such that the secondthermoplastic material contacts the second portion of the textilecomponent; (f) exposing the first seam support member and the firstportion of the textile component to conditions sufficient to engage thefirst seam support member with the first portion of the textilecomponent via the first thermoplastic material to thereby provide afirst exposed composite edge corresponding to a location of the layeredfirst exposed edge and the third exposed edge; (g) exposing the layeredsecond seam support member and the second portion of the textilecomponent to conditions sufficient to engage the second seam supportmember with the second portion of the textile component via the secondthermoplastic material to thereby provide a second exposed compositeedge corresponding to a location of the layered second exposed edge andthe fourth exposed edge; and (h) joining the first exposed compositeedge to the second exposed composite edge in an abutting edge joint.

More specific aspects of this invention relate to methods of formingseams in upper members for articles of footwear. Such methods mayinclude: (a) providing an upper construction including a first portionhaving a first exposed edge and a second portion having a second exposededge, wherein the upper construction may be composed of one or moreseparate upper pieces; (b) providing a first seam support memberincluding a first thermoplastic material, wherein the first seam supportmember is shaped to include a third exposed edge that matches at least aportion of the first exposed edge; (c) providing a second seam supportmember including a second thermoplastic material (the secondthermoplastic material may be the same as or different from the firstthermoplastic material), wherein the second seam support member isshaped to include a fourth exposed edge that matches at least a portionof the second exposed edge; (d) placing the first seam support member onthe first portion of the upper construction such that the first exposededge and the third exposed edge are in a layered relationship and suchthat the first thermoplastic material contacts the first portion of theupper construction; (e) placing the second seam support member on thesecond portion of the upper construction such that the second exposededge and the fourth exposed edge are in a layered relationship and suchthat the second thermoplastic material contacts the second portion ofthe upper construction; (f) exposing the first seam support member andthe first portion of the upper construction to conditions sufficient toengage the first seam support member with the first portion of the upperconstruction via the first thermoplastic material to thereby provide afirst exposed composite edge corresponding to a location of the layeredfirst exposed edge and the third exposed edge; (g) exposing the layeredsecond seam support member and the second portion of the upperconstruction to conditions sufficient to engage the second seam supportmember with the second portion of the upper construction via the secondthermoplastic material to thereby provide a second exposed compositeedge corresponding to a location of the layered second exposed edge andthe fourth exposed edge; and (h) joining the first exposed compositeedge to the second exposed composite edge in an abutting edge joint.

The upper construction or other textile component may be provided in anydesired manner without departing from this invention. For example, itmay be obtained from a third party source. Alternatively, it may bemanufactured, e.g., by cutting out one or more pieces from a blank or apiece of material (such as by die cutting, laser cutting, hand cutting,etc.).

Similarly, the first and second seam support members may be provided inany desired manners without departing from this invention. As one morespecific example, they may be obtained from a third party source.Alternatively, they may be manufactured. As some more specific examples,the seam support members may be manufactured by: (a) applying a firstthermoplastic film material to a first seam support material; (b)applying a second thermoplastic film material to a second seam supportmaterial (wherein the second thermoplastic film material may be the sameas or different from the first thermoplastic film material and whereinthe second seam support material may be the same as or different fromthe first seam support material); (c) cutting the first seam supportmaterial and the first thermoplastic film into a shape that includes athird exposed edge that matches at least a portion of the first exposededge provided on the upper construction or other textile component; and(d) cutting the second seam support material and the secondthermoplastic film into a shape that includes a fourth exposed edge thatmatches at least a portion of the second exposed edge provided on theupper construction or other textile component. The cutting steps may beperformed in any desired manner, such as by die cutting, laser cutting,hand cutting, etc. Optionally, if desired, the seam support members maybe cut from a single piece of material that includes the first andsecond thermoplastic materials and the first and second seam supportmaterials.

The exposing steps also may comprise a variety of features withoutdeparting from this invention. For example, the exposing steps may takeplace simultaneously (optionally using the same apparatus at the sametime or in separate apparatuses) or separately. The exposing steps mayinclude: exposing the first seam support member and the first portion ofthe upper construction (or other textile component) and/or the secondseam support member and the second portion of the upper construction (orother textile component) to at least one of increased heat ortemperature conditions, increased pressure conditions, laser radiation,radio frequency energy, ultrasonic radiation, other radiation, etc.

The abutting edge joint may be made in any desired manner, including thevarious manners described above, without departing from this invention.In at least some example methods according to this invention, the“joining” step will include sewing the first exposed composite edge tothe second exposed composite edge (e.g., via a zig-zag stitch) tothereby form a seam. If desired, the composite edges may be joined via athread material (in the sewn stitch) made from a material that allowsthe thread material to be at least partially melted, absorbed,concealed, or masked in the seam. This may be accomplished, for example,by using a thermoplastic polyurethane thread to make the joint and thenexposing the thread to at least one of increased heat or temperatureconditions, increased pressure conditions, laser radiation, radiofrequency waves, other radiation, etc., to thereby essentially melt thethread (or otherwise absorb or conceal the thread) within the remainingmaterial in the joint. The exposing step(s) may take place either beforeor after the joining step takes place (optionally, at the same time thatthe thread is melted or otherwise treated, if such thread treatmentsteps are included in the method).

Aspects of this invention further relate to seams, textile components(including such seams), upper members (including such seams), articlesof manufacture (including such seams), and/or articles of footwear(including such seams) made using any of the various methods (andvariations thereon) described above and described in more detail below.

B. SPECIFIC EXAMPLES OF STRUCTURES AND METHODS ACCORDING TO THEINVENTION

Features and aspects of this invention now will be described in moredetail with specific reference to FIGS. 1 through 10C. The reader isadvised, however, that this detailed description and the accompanyingdrawings are provided merely to illustrate examples and features of theinvention. The specific description and drawings should not be construedas limiting the invention.

1. The Upper Material

Aspects of this invention may be practiced using any desired type ofupper material, including conventional upper materials that are knownand used in the art. Such materials may include, for example: leather,synthetic leather, suede, polyesters, other polymeric materials, wovenmaterials, non-woven materials, knitted materials, fabrics, textiles,etc., including combinations of such materials. When upper members aremade from multiple different pieces or parts, each piece or part neednot be made from the same material (i.e., a single upper constructionmay include multiple different types of materials).

In some example structures according to this invention, however, verylightweight, thin, and/or breathable (e.g., air permeable) fabrics ortextiles may be used for upper members. One specific example of asuitable lightweight and/or breathable material that may be used inaccordance with examples of this invention is a “spacer mesh” material100, as illustrated in FIG. 1. A spacer mesh material 100 in accordancewith at least some examples of this invention includes a fabric producedby sandwiching two fabric pieces 102 and 104 together (optionallydissimilar fabrics) while keeping some space between them. The twofabric pieces 102 and 104 may be selected to provide desired propertiesfor the upper member, such as a soft, comfortable feel for the innerfabric piece 104 (which will form the shoe interior) and toughness,abrasion resistance, durability, stain resistance, etc., for theexterior fabric piece 102.

The space between the fabric pieces 102 and 104 may be maintained byproviding a mesh material layer 106 between the two fabric pieces 102and 104. The mesh material layer 106 may include several closely spacedholes, e.g., woven into a knit fabric making up the mesh layer 106. Thevarious fabric layers may be joined together in any desired mannerwithout departing from this invention, including through the use ofadhesives. Alternatively, if desired, two or more of the various layers102, 104, and 106 may be integrally formed together during a knitting orweaving process that results in production of the fabric material 100.This resulting fabric material 100 is porous, breathable, comfortable,and cool. These three-dimensional spacer mesh fabrics 100 may vary inthickness, but they are generally from 1 to 15 mm thick.

Various spacer mesh fabrics are known and are commercially available,such as fabrics used in car seat covers available under the nameCOVERKING® (available from Shrin Corporation of Santa Ana, Calif.).Other commercial sources of spacer mesh fabric, or other desired fabricor other materials for the upper construction (e.g., single layered ormultilayered materials) may be used without departing from thisinvention.

2. Formation of the Upper Pieces

An upper construction may be formed using the upper material, such asthe spacer mesh fabric 100 described above. As illustrated in FIG. 2, anupper member 200 may be cut from a fabric blank 202 formed from thedesired upper material, such as spacer mesh material 100 describedabove. Any desired cutting operation may be performed without departingfrom this invention. In this illustrated example, the upper member 200is cut from a fabric blank 202 using laser cutting techniques. This isrepresented in FIG. 2 by a laser source 204 that produces a beam B. Thebeam B may be scanned across the fabric blank 202 at appropriatelocations (shown by dashed lines in FIG. 2) to thereby cut out thedesired upper member 200 shape from the blank 202. The scanning systemin FIG. 2 is generally represented by scanning mirror 206 (although anydesired type of scanning system may be used without departing from thisinvention). Laser cutting systems and scanning systems for laser cuttingof fabrics and other materials are conventionally known and used. Thoseskilled in the art can determine the various laser cutting parametersfor specific materials (such as scanning speed, laser power, beamdiameter, etc.) through the use of routine experimentation. As otheralternatives, however, the fabric blank 202 may be cut into the desiredshape by any other desired cutting methods or techniques, such as bydie-cutting, rotary cutting, hand cutting, etc.

While illustrated as a single piece construction, uppers may have anydesired constructions, number of pieces, shapes, sizes, and the likewithout departing from this invention. Additionally, a single blank 202may have multiple upper members 200 or upper member pieces cut therefromwithout departing from this invention.

FIG. 3 illustrates one example of an upper member 200 that may beproduced in accordance with this invention. In this example structure,the upper member 200 constitutes a single piece that includes: a medialside and lace eyelet section 212, a lateral side and lace eyelet section214, a toe portion 216, a rear heel portion 218, and footbed portions220 and 222. Although not shown in FIG. 2 or 3, the upper constructionmay additionally include a tongue member, e.g., integrally formed aspart of the one piece upper member 200 (e.g., extending from one of theeyelet sections 212 or 214 or from the toe portion 216), or separatelyformed (from the same upper material blank 202 or from a different blankor even a different upper material). The upper member 200 may be shapedand stitched in the necessary places (optionally along with a tonguepart, as mentioned above) to provide a final upper construction. As oneexample in the illustrated upper member 200, edge 224 may be engagedwith edge 226 when forming the upper construction. Various examples ofseam formation features of the invention will be described in moredetail below.

3. The Seam Support Member

As mentioned above, the upper material, in at least some examplestructures according to this invention, may be selected so as to be verylightweight, thin, breathable (e.g., air permeable), soft, and/orcomfortable. Such materials, however, do not always have great strength,durability, or structural integrity. For example, such materials may nothave adequate strength or structural integrity to support the seams thatmay be necessary to form an upper construction and/or to maintain theupper construction in the desired shape. As one more specific example,when sewn, the threads of the seam may tend to tear or pull through thefabric thus splitting the seam. Additionally or alternatively, thematerial may be layered before being sewn (in an effort to provideadequate thickness and strength to support a seam), which can cause abulky and uneven seam and discomfort to the wearer (such a constructionalso utilizes more upper material). As another example, such thin andsoft materials may be inadequate to hold the upper's shape when it isnot being worn (such that the upper appears “deflated”), which can causedifficulties in putting on the article of footwear.

Therefore, in accordance with at least some examples of this invention,the upper members may be modified to include seam support members (andoptionally other support members) at various locations in the footwearstructure. When utilized as a seam support member, the material may be amaterial that is capable of maintaining a stable edge and capable ofsupporting a sewn seam (e.g., without readily pulling the seam apartunder normal usage forces). While a variety of materials may be used asseam support materials without departing from this invention, in someexample structures according to the invention the seam support materialmay be leather, synthetic leather, suede, synthetic suede materials,polyesters, other polymer based fabrics and materials, thick fabricmaterials, and the like. One suitable material is an ultra-microfiber,suede-like, non-woven fabric material known as Ecsaine®, which iscommercially available from Toray Industries, Inc.

As illustrated in conjunction with FIG. 4, a seam support member blank400 in accordance with at least some examples of this invention maycomprise a two layer construction. One layer of this blank 400constitutes a seam support material 402, e.g., of the types describedabove, such as an Ecsaine® ultra-microfiber, suede-like, non-wovenfabric material available from Toray Industries, Inc. The second layer404 is an adhesive film material (such as a thermoplastic polyurethanematerial) that will enable engagement of the seam support material 402to the upper member 200. While any desired adhesive film material 404may be used without departing from this invention, in accordance with atleast some examples of this invention, the adhesive film material 404will be a Bemis material available from Bemis Associates, Inc., such asBemis's Sewfree® material.

Production of the seam support member blank 400 (e.g., the combinationof the seam support material 402 and the adhesive film material 404)will be described in more detail in conjunction with FIGS. 4 and 5.First, the overall seam support member blank 400 is prepared. This maybe accomplished by applying an adhesive film material layer 404 to aseam support material layer 402 to make a composite sheet of the seamsupport member blank 400. Optionally, in accordance with at least someexamples of this invention, the adhesive features of the adhesive filmmaterial layer 404 may be used to hold these layers 402 and 404 togetherwithout further treatment. In other examples, however, some type ofadditional treatment (such as ultrasonic, radio frequency, laser, orother radiation treatments, heat treatment, pressure treatment, etc.)may be used to help bind these materials 402 and 404 together. Ifdesired, release paper may be provided on one or both sides of theadhesive film material 404 to prevent it from sticking to objects beforeit is desired.

Once the seam support member blank 400 is prepared, it then may be cutinto the desired shape for the seam support member 500, as shown in FIG.5. Any desired cutting operation may be performed without departing fromthis invention. In this illustrated example, the final seam supportmember 500 is cut from a seam support member blank 400 using lasercutting techniques. This is represented in FIG. 5 by a laser source 502that produces a beam B. The beam B may be scanned across the seamsupport member blank 400 at appropriate locations (shown by dashed linesin FIG. 5) to thereby cut out the desired seam support member 500 shapefrom the blank 400. The scanning system in FIG. 5 (which may be the sameas or different from the scanning system shown in FIG. 2) is generallyrepresented by scanning mirror 506. As noted above, laser cuttingsystems and scanning systems for laser cutting of fabrics and othermaterials are conventionally known and used, and those skilled in theart can determine the various laser cutting parameters for specificmaterials (such as scanning speed, laser power, beam diameter, etc.)through the use of routine experimentation. As other alternatives,however, the blank 400 may be cut into the desired shape by any otherdesired methods or techniques, such as by die-cutting, rotary cutting,hand cutting, etc.

While the example process described above includes cutting the adhesivefilm material 404 and the seam support material 402 simultaneously in asingle cutting operation, these materials also may be cut separately, ifdesired, and then engaged with one another without departing from thisinvention. Also, if desired, this cutting step may be combined andperformed simultaneous with the cutting of the upper member describedabove.

FIG. 6 illustrates the final cut out seam support member 500 preparedthrough this example process. In this example structure 500, the seamsupport member 500 constitutes a single piece that includes: a medialside lace eyelet section 512, a lateral side lace eyelet section 514,and a rear heel portion 518. Furthermore, this seam support member 500includes an edge 524 (which corresponds to edge 224 of upper member 200)that will be engaged with edge 526 (which corresponds to edge 226 ofupper member 200) when forming the upper construction.

While not necessarily supporting an eventual seam in the overall uppermember construction, the seam support member 500 may include additionalportions that support various edges of the overall upper construction.For example, edge 528 of the seam support member 500 may be providedalong the foot-receiving opening of the article of footwear to provide astable edge and to prevent fraying of the upper member material alongthat edge. Additionally, seam support material may be provided at otherdesired locations in the upper structure, e.g., to provide support, toprovide decoration, etc.

FIGS. 5 and 6 show another feature that may be used in structures andmethods according to this invention. As shown, the seam support member500 may include various design features cut into it (such as the cut outoctagon member 530). In this manner, if the seam support member 500 isprovided in a color that differs from the underlying upper materialcolor, the upper material will show through portions of the seam supportmember 500 (such as through the cut out octagon member 530), to providean interesting aesthetic design and appearance. Any desired designelement 530 may be cut into the seam support member structure 500, suchas shapes, logos, alpha-numeric characters, etc.

4. Forming the Composite Upper Member

FIGS. 7A and 7B illustrate formation of a composite upper memberincluding the upper material and a seam support member in accordancewith at least some examples of this invention. As shown in thesefigures, in this example process, the cut out seam support member 500 isaligned with and overlaid onto the cut out upper member 200 with thethermoplastic film material 404 side of the seam support member 500(after any optional release paper has been removed) in direct contactwith the surface of the upper member 200. These materials may sticktogether due to the adhesive nature of the thermoplastic film material404. These members 200 and 500 may be joined together such that theedges of the desired seam support member 500 match up with the desirededges of the upper member 200. Specifically, as illustrated in thesefigures, the seam support member 500 and the upper member 200 may bealigned such that the seam edge 524 of the seam support member 500overlays and aligns with the seam edge 224 of the upper member 200 andsuch that the seam edge 526 of the seam support member 500 overlays andaligns with the seam edge 226 of the upper member 200. Likewise, asillustrated in these figures, the eyelet areas 212 and 214 of the uppermember 200 are arranged to align with the eyelet areas 512 and 514 ofthe seam support member 500. Other desired edges also may be aligned andoverlaid.

Once properly aligned, in accordance with at least some examples of thisinvention, the upper member 200 and seam support member 500 may be morepermanently engaged with one another. This may be accomplished by“welding” the upper member 200 to the seam support member 500 using thethermoplastic film material 404 of the seam support material 500. This“welding” or activation step may be accomplished, in accordance with atleast some examples of this invention, by laser “welding,” i.e., byexposing the layered upper member 200 and seam support member 500 tolaser radiation (as generally illustrated in FIG. 7B) using a lasersource 700 which scans over the surface of the combined upper member 200and seam support member 500 using a scanning mechanism 702. The laserand scanning systems used in the procedure of FIG. 7B may be the same asor different from the systems shown in FIGS. 2 and 5. As noted above,laser treatment and scanning systems of this type are conventionallyknown and used, and those skilled in the art can determine the variouslaser treatment parameters for specific materials (such as scanningspeed, laser power, beam diameter, etc.) through the use of routineexperimentation.

Other systems and/or treatment techniques may be used to engage theupper member 200 and seam support member 500 with one another. Forexample, the members 200 and 500 may be engaged with one another simplyusing adhesives or cements, optionally with additional heating orpressure application treatments to activate the adhesives or cements. Asadditional examples, radio frequency energy, ultrasonic radiation, orother radiation treatments, may be used to engage the upper member 200with the seam support member 500.

After engagement of the upper member 200 and seam support member 500,the resulting composite member 710 (including composite edges 224/524and 226/526) may be ready for stitching and/or otherwise formation intoan upper member for an article of footwear. Examples of stitching and/orseam forming procedures in accordance with this invention will bedescribed in more detail below.

Any or all of the seams of the upper construction may be made to includea seam support member portion. Similarly, any or all edges of the upperconstruction (or any or all exposed edges of the upper construction)also may be made to include a seam support member portion (even if thoseedges will not include a seam, but rather, the seam support member ispresent simply for structural support and/or to prevent fraying). Ifdesired, the seam support material at an edge (such as edge 528) may besized sufficiently so that it may be folded over to completely cover theexposed edge of the upper member 200. Also, while the present exampleshows a single seam support member 500 for a single upper, any number ofupper member pieces and/or seam support member pieces may be provided ina single overall upper construction without departing from thisinvention.

5. Forming Seams

As noted above, aspects of this invention relate to providing one ormore of the seams in the upper member for an article of footwear in theform of an abutting edge joint seam. FIGS. 8A through 8D illustrate anexample of making such a seam.

As illustrated in FIG. 8A, the production of the abutting edge joint(e.g., a butt seam) in accordance with at least some examples of thisinvention includes starting with two edges 824 and 826 of upper materialthat are to be engaged (e.g., the edges 824 and 826 may be located on asingle piece of upper material or two (or more) separate pieces of uppermaterial). The edges 824 and 826 may be straight or curved or shaped inany desired manner, and the edges 824 and 826 may generally matetogether with one another. The edge 824 in this illustrated example maycomprise the composite edge of the upper member 500 from FIGS. 7A and7B, including the exposed edges 224 and 524 of the upper member 200 andthe seam support member 500, respectively (the term “exposed” as usedherein in this context refers to the open or unshielded character of anedge, not the fact that the edge may have been exposed to radiation,heat, or other conditions, e.g., during one or more of the stepsdescribed above, and not to whether or not the edge will be exposed inthe final footwear construction). Likewise, the edge 826 in thisillustrated example may comprise the composite edge of the upper member500 from FIGS. 7A and 7B, including the exposed edges 226 and 526 of theupper member 200 and the seam support member 500, respectively.

The two mating edges 824 and 826 are brought together such that theedges match up with one another, as illustrated in FIG. 8B, along anabutting edge. This type of arrangement is advantageous because, asillustrated in FIG. 8B, this arrangement provides a smooth lower surface802, and this smooth lower surface 802 will correspond to the interiorsurface of the upper that contacts the wearer's foot.

Once correctly positioned, the two mating edges 824 and 826 then arejoined to one another. While any desired joining process may be usedwithout departing from this invention, in this illustrated example thetwo mating edges 824 and 826 are joined together using a sewn seam 810,as illustrated in FIG. 8C. While any desired type of sewing processand/or stitch may be used without departing from this invention,including conventional sewing processes and conventional stitches as areknown and used in the art, in this illustrated example, the edges 824and 826 are joined together in a sewn seam 810 using a zig-zag stitch.The sewing step may take place using a sewing machine, includingconventional sewing equipment as is known and used in the art.

FIG. 8D illustrates the underside or lower surface 802 of the abuttingedge joint formed in the procedure described in FIGS. 8A through 8C. Asshown, the lower surface 802 remains substantially smooth, with no (oressentially no) overlap of the two edges 824 and 826 making up the seam810. This lack of overlapping upper and seam support materials at theseam 810 enhances the comfort of the upper where it contacts thewearer's foot, because overlapping seams tend to exert more pressure oncontact areas with the foot (than a non-overlapping seam), which cancause discomfort, irritation, blisters, etc. In addition, the lack ofoverlapping upper materials at the seam 810 reduces the amount ofmaterial in the overall upper construction, which reduces costs, waste,weight, etc. Optionally, if desired, a thin layer of thermoplastic orother film material 850 may be placed over at least some portions of theinterior surface of the seam 810 (e.g., an adhesive film on the interiorsurface 802 of the upper construction) to further flatten and/or maskthe feel of the sewn seam on the user's foot.

FIG. 8E illustrates another potential feature that may be included inupper constructions and/or methods in accordance with examples of thisinvention. If desired, the thread material 812 of the sewn seam 810(e.g., the thread material 812 of the zig-zag stitch) may be made from amaterial that allows for further treatment of the stitch and the seam810. For example, the thread material 812 may be made from athermoplastic material (e.g., similar to or the same as thethermoplastic film material 404 of FIG. 4). This thread material 812 maybe further treated, e.g., by application of heat or pressure; byexposure to laser radiation, ultrasonic radiation, or other radiation;etc., such that the thread material 812 melts or otherwise becomes atleast partially absorbed, concealed, or masked in the final seam 820.This treatment step is generally represented in FIG. 8E by the exposureor treatment system 814, and the at least partial absorption, masking,or concealment is represented in FIG. 8E by graying out the threadmaterial 812 and showing it in broken lines. As noted above, if desired,a thin layer of thermoplastic or other film material may be placed overat least some portions of the interior surface of the seam 810 (e.g., anadhesive film on the interior surface 802 of the upper construction),which can provide a base material on the underside 802 of the upperconstruction into which the thread material 812 may be melted orotherwise at least partially absorbed, concealed, or masked. All or onlysome portions of the thread materials 812 may be further treated in thismanner.

6. Alternative Upper Constructions

FIGS. 1 through 8E illustrate various examples of an upper constructionin which the upper is made from a single piece and it includes footbedportions 220 and 222 integrally formed as part of the upper material200. Many variations in the upper construction are possible withoutdeparting from this invention. For example, as illustrated in FIG. 9, anupper member 900 may be formed with a similar construction in a similarmanner as described above (where relevant, the same reference numbersare used in FIG. 9 as used, for example, in FIGS. 1-8E, and particularlyin FIGS. 7A and 7B, to represent the same parts and procedures asdescribed above in conjunction with FIGS. 1-8E), but instead ofincluding the footbed portions 220 and 222 as part of the uppermaterial, the footbed is provided as a separate strobel member 902 thatis engaged with the composite upper material 200 and seam supportmaterial 500. Any manner of engaging the strobel member 902 with thecomposite upper material 200 and seam support material 500 may be usedwithout departing from this invention, including manners that areconventionally known and used in the art, such as sewing or stitching,fusing techniques, mechanical connectors, etc. Optionally, if desired,all or some portion of the strobel member 902 may be joined to thecomposite upper material 200 and seam support material 500 using anabutting edge joint, e.g., as described above. The strobel member 902may be considered as part of the overall upper construction 900, or itmay be considered as a separate part from the upper construction.

The strobel member 902, when used, may be made of any desired materialsand in any desired constructions without departing from this invention,including from conventional materials and in conventional constructionsas are known and used in the art. Examples of such materials include oneor more layers of fabric materials, foam materials (e.g., polyurethanefoam, ethylvinylacetate foam, etc.), or combinations thereof. In someinstances, the strobel member 902 can help provide shape to the overallupper construction.

Additionally, if desired (as illustrated by broken lines in FIG. 9), theupper member 200 may be made from multiple pieces. This is shown by theadditional optional seam 904 shown in FIG. 9, which separates out aseparate toe box cover member 906 that may be joined with the remainderof the upper member 200. Any desired manner of engaging the variousparts of an upper member together may be used without departing fromthis invention, including conventional engagement techniques as areknown and used in the art. Also, if desired, the various parts of theupper member may be engaged together using an abutting edge joint, e.g.,in the manners described above in conjunction with FIGS. 8A through 8E.Any number of seams and/or any number of upper pieces may be joinedtogether for an upper construction in accordance with at least someexamples of this invention, and any number of seams in suchconstructions may be provided as abutting edge joints, e.g., of thetypes described above.

7. Footwear Constructions

FIGS. 10A through 10C illustrate an example article of footwear 1000 andfeatures thereof that may be produced in accordance with examples ofthis invention. FIG. 10A illustrates the lateral side of the article offootwear 1000, FIG. 10B illustrates the medial side, and FIG. 10Cprovides additional details relating to the instep and tongue area ofthis example structure 1000. As shown in FIGS. 10A and 10B, the articleof footwear 1000 includes an upper member 1002, e.g., of the typesdescribed above, wherein at least one seam is produced using an abuttingedge joint. The upper member 1002 may be engaged with a sole structure1004. Any desired sole structure 1004 may be provided without departingfrom this invention, including any desired sole materials, combinationsof materials, constructions, and the like, including conventional solestructures, materials, combinations of materials, and constructions, asare known and used in the art. As some more specific examples, the solestructure 1004 may include one or more of: one or more midsole elements,one or more insole elements, one or more innersole boards, one or moreoutsole elements, one or more impact-attenuating column members, one ormore mechanical type impact-attenuating members, one or morefluid-filled bladders, etc. Sole structures designed for any desiredsport, athletic activity, or other activity or use may be included aspart of the footwear structure 1000 without departing from thisinvention.

The upper member 1002 may be engaged with the sole structure 1004 in anydesired manner without departing from this invention, including inmanners that are conventionally known and used in the art. Such methodsmay include, for example, the use of cements or adhesives; the use ofsewing or stitching; the use of fusing techniques; the use of mechanicalconnectors; etc.

As described above, the upper member 1002 may include a fabric or otherupper material 1002 a (e.g., a spacer mesh fabric element as describedabove), in one or more separate pieces, including thin and/orlightweight upper materials that typically are not able to stablysupport a seam on their own. The upper member 1002 further may includethe seam support material 1002 b, in one or more separate pieces, e.g.,of the types described above. As shown in the figures, in addition toproviding a support material for supporting an abutting edge joint seam(such as seams 1006, 1008, and 1010 utilizing zig-zag stitches), thesupport material 1002 b may be provided at other locations where supportis desired, such as along the edges of the foot-receiving opening 1012,in the toe area 1014, along the lace eyelet areas 1016 and 1018, as atleast part of the tongue member 1020, in the heel area 1022, etc.Moreover, if the seam support material 1002 b is colored and/or textureddifferent from the upper fabric material 1002 a, the seam supportmaterial 1002 b may be provided on the upper material 1002 a in a mannerso as to provide an interesting aesthetic design for the upper. Forexample, if desired, one or more openings may be provided in the seamsupport material 1002 b (such as opening 1024), and the opening(s) maybe shaped so as to form a design, pattern, logo, alphanumeric character,or the like (e.g., due to the upper material 1002 a (or anothermaterial) showing through the opening 1024 provided in the seam supportmaterial). As another example, one or more pieces 1026 of seam supportmaterial 1002 b (or another material) may be provided on the uppermaterial 1002 a, in desired shape(s) and location(s) so as to form adesign, pattern, logo, alphanumeric character, or the like. Other waysof decorating the article of footwear 1000, including conventionaldecorative ways, may be used without departing from this invention.

As mentioned above, a separate tongue member (made of the same ordifferent materials from the remainder of the upper member) may beprovided and attached to the upper construction without departing fromthis invention. Alternatively, if desired, a tongue member 1020 may beintegrally formed as part of the upper member construction. As bestillustrated in FIG. 10C, in this example structure 1000, the tonguemember 1020 is integrally formed with at least a portion of the medialside 1030 of the upper construction. Specifically, the tongue member1020 integrally extends from the medial side eyelet area 1018, and it isjoined to the upper structure along seam 1008. In order to allow aconventional shoe lace to be engaged with the upper 1002, the medialside eyelet area 1018 includes two eyelet holes 1032 at each laceengagement location (one in which the free end of the lace enters andone in which the free end of the lace exits), whereas the lateral sideeyelet area 1016 includes a single eyelet hole 1032 at each laceengagement location. Alternatively, if desired, the tongue member 1020could be integrally formed from the lateral side 1034 of the article offootwear 1000 or from the toe portion 1036 of the article of footwear1000.

As shown in FIG. 10C, the tongue member 1020 may constitute multiplepieces joined together (e.g., at seam 1010), wherein the various piecesof the tongue member form parts of different pieces of the uppermaterial. Other tongue constructions, including single piece tongueconstructions that are integrally formed with or separate from theremainder of the upper member, are possible without departing from thisinvention.

C. CONCLUSION

Articles of footwear in accordance with at least some examples of thisinvention may include structural elements or other components that arenot specifically described above or illustrated in the figures. Suchelements or components may include, but are not necessarily limited to:heel counters or other support members; shoe laces or other securingmembers; toe caps; connectors for engaging the footwear to a foot; archsupport members; orthotics; other support members (in the sole or theupper); etc. Also, the footwear may be made in any desired style,including athletic footwear, dress footwear, low rise footwear, high topfootwear, etc.

At least some example structures according to this invention provide alightweight, breathable material with strong, smooth seam structures.The ability to form seams in the manners described above allows afootwear producer to pattern the pieces of upper material around thelast, which can help give the upper material a better shape withouthaving to excessively stretch the material around the last. If desired,the upper material could be shaped directly on the last and/or bettertailored to fit around the last. As yet additional options, if desired,the seam(s) may be made while the upper material component(s) is (are)on the last. These features can help provide a very comfortable finalupper structure.

Also, given the benefit of this disclosure, one skilled in the art couldreadily apply aspects of this invention to production of other articlesof manufacture, such as other articles of apparel. For example, thisinvention could be used for producing seams in hats, gloves, shirts,pants, shorts, socks, athletic wear (e.g., uniforms or apparel forspecific sports), and the like.

While the invention has been described in detail in terms of specificexamples including presently preferred modes of carrying out theinvention, those skilled in the art will appreciate that there arenumerous variations and permutations of the above described systems andmethods. Thus, the spirit and scope of the invention should be construedbroadly as set forth in the appended claims.

1. A method of forming a seam in an upper member for an article offootwear, comprising: applying a first thermoplastic film material to afirst seam support material; applying a second thermoplastic filmmaterial to a second seam support material, wherein the secondthermoplastic film material may be the same as or different from thefirst thermoplastic film material, and wherein the second seam supportmaterial may be the same as or different from the first seam supportmaterial; providing an upper construction for an article of footwearincluding a first portion having a first exposed edge of a spacer meshmaterial and a second portion having a second exposed edge of a spacermesh material, wherein the upper construction is made from one or moreupper pieces; cutting the first seam support material and the firstthermoplastic film into a shape that includes a third exposed edge thatmatches at least a portion of the first exposed edge; cutting the secondseam support material and the second thermoplastic film into a shapethat includes a fourth exposed edge that matches at least a portion ofthe second exposed edge; placing the first seam support material on thefirst portion of the upper construction such that the first exposed edgeand the third exposed edge are in a layered relationship and such thatthe first thermoplastic film contacts the first portion of the upperconstruction; placing the second seam support material on the secondportion of the upper construction such that the second exposed edge andthe fourth exposed edge are in a layered relationship and such that thesecond thermoplastic film contacts the second portion of the upperconstruction; exposing the layered first seam support material and thefirst portion of the upper construction to conditions sufficient toengage the first seam support material with the first portion of theupper construction via the first thermoplastic film to thereby provide afirst exposed composite edge corresponding to a location of the layeredfirst exposed edge and the third exposed edge; exposing the layeredsecond seam support material and the second portion of the upperconstruction to conditions sufficient to engage the second seam supportmaterial with the second portion of the upper construction via thesecond thermoplastic film to thereby provide a second exposed compositeedge corresponding to a location of the layered second exposed edge andthe fourth exposed edge; and joining the first exposed composite edge tothe second exposed composite edge in an abutting edge joint.
 2. A methodaccording to claim 1, wherein the joining includes sewing the firstexposed composite edge to the second exposed composite edge via azig-zag stitch.
 3. A method according to claim 2, wherein the zig-zagstitch is formed using a thread material made from a thermoplasticmaterial.
 4. A method according to claim 3, further comprising: treatingthe thread material so that it melts or becomes at least partiallyabsorbed in the first and second seam support materials.
 5. A methodaccording to claim 1, wherein at least one of the cutting steps includesdie-cutting.
 6. A method according to claim 1, wherein at least one ofthe cutting steps includes laser cutting.
 7. A method according to claim1, wherein the exposing steps take place simultaneously.
 8. A methodaccording to claim 1, wherein the exposing steps include exposing thelayered first seam support material and the first portion of the upperconstruction to at least one of increased heat or pressure conditions,and exposing the layered second seam support material and the secondportion of the upper construction to at least one of increased heat orpressure conditions.
 9. A method according to claim 1, wherein theexposing steps include exposing the layered first seam support materialand the first portion of the upper construction to at least one of alaser beam or radio frequency waves, and exposing the layered secondseam support material and the second portion of the upper constructionto at least one of a laser beam or radio frequency waves.
 10. An uppermember for an article of footwear including at least one seam made bythe method of claim
 1. 11. A method of forming a seam in an upper memberfor an article of footwear, comprising: providing an upper constructionfor an article of footwear including a first portion having a firstexposed edge of a spacer mesh material and a second portion having asecond exposed edge of a spacer mesh material, wherein the upperconstruction is made from one or more upper pieces; providing a firstseam support member including a first thermoplastic material, whereinthe first seam support member is shaped to include a third exposed edgethat matches at least a portion of the first exposed edge; providing asecond seam support member including a second thermoplastic material,wherein the second thermoplastic material may be the same as ordifferent from the first thermoplastic material, and wherein the secondseam support member is shaped to include a fourth exposed edge thatmatches at least a portion of the second exposed edge; placing the firstseam support member on the first portion of the upper construction suchthat the first exposed edge and the third exposed edge are in a layeredrelationship and such that the first thermoplastic material contacts thefirst portion of the upper construction; placing the second seam supportmember on the second portion of the upper construction such that thesecond exposed edge and the fourth exposed edge are in a layeredrelationship and such that the second thermoplastic material contactsthe second portion of the upper construction; exposing the first seamsupport member and the first portion of the upper construction toconditions sufficient to engage the first seam support member with thefirst portion of the upper construction via the first thermoplasticmaterial to thereby provide a first exposed composite edge correspondingto a location of the layered first exposed edge and the third exposededge; exposing the layered second seam support member and the secondportion of the upper construction to conditions sufficient to engage thesecond seam support member with the second portion of the upperconstruction via the second thermoplastic material to thereby provide asecond exposed composite edge corresponding to a location of the layeredsecond exposed edge and the fourth exposed edge; and joining the firstexposed composite edge to the second exposed composite edge in anabutting edge joint.
 12. A method according to claim 11, wherein thejoining includes sewing the first exposed composite edge to the secondexposed composite edge via a zig-zag stitch.
 13. A method according toclaim 12, wherein the zig-zag stitch is formed using a thread materialmade from a thermoplastic material.
 14. A method according to claim 13,further comprising: treating the thread material so that it melts orbecomes at least partially absorbed in the first and second seam supportmembers.
 15. A method according to claim 11, wherein the exposing stepstake place simultaneously.
 16. A method according to claim 11, whereinthe exposing steps include exposing the first seam support member andthe first portion of the upper construction to at least one of increasedheat or pressure conditions, and exposing the second seam support memberand the second portion of the upper construction to at least one ofincreased heat or pressure conditions.
 17. A method according to claim11, wherein the exposing steps include exposing the first seam supportmember and the first portion of the upper construction to at least oneof a laser beam or radio frequency waves, and exposing the second seamsupport member and the second portion of the upper construction to atleast one of a laser beam or radio frequency waves.
 18. An upper memberfor an article of footwear including at least one seam made by themethod of claim 11.